US7006356B2 - Driving system with converter control for low-voltage three-phase motors - Google Patents

Driving system with converter control for low-voltage three-phase motors Download PDF

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Publication number
US7006356B2
US7006356B2 US10/429,287 US42928703A US7006356B2 US 7006356 B2 US7006356 B2 US 7006356B2 US 42928703 A US42928703 A US 42928703A US 7006356 B2 US7006356 B2 US 7006356B2
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United States
Prior art keywords
printed circuit
circuit board
converter control
cover
casing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime, expires
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US10/429,287
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English (en)
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US20040022041A1 (en
Inventor
Ulf Bergmann
Nils-Peter Hansen
Frank Hörmann
Benjamin Jonas
Michael Knieriem
Olaf Lenz
Rüdiger Schwarz
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Jungheinrich AG
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Jungheinrich AG
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Assigned to JUNGHEINRICH AKTIENGESELLSCHAFT reassignment JUNGHEINRICH AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BERGMANN, ULF, HANSEN, NILS-PETER, HORMANN, FRANK, JONAS, BENJAMIN, KNIERIEM, MICHAEL, LENZ, OLAF, SCHWARZ, RUDIGER
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
    • H05K7/1427—Housings
    • H05K7/1432—Housings specially adapted for power drive units or power converters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
    • H05K7/1427—Housings
    • H05K7/1432—Housings specially adapted for power drive units or power converters
    • H05K7/14322—Housings specially adapted for power drive units or power converters wherein the control and power circuits of a power converter are arranged within the same casing
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
    • H05K7/1427—Housings
    • H05K7/1432—Housings specially adapted for power drive units or power converters
    • H05K7/14329—Housings specially adapted for power drive units or power converters specially adapted for the configuration of power bus bars
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/14—Structural association of two or more printed circuits
    • H05K1/144—Stacked arrangements of planar printed circuit boards

Definitions

  • the transformer When using three-phase motors for battery-operated floor conveyors a transformer is naturally required, which generates the three-phase alternating voltage from the battery voltage.
  • the transformer conveniently contains three half-bridges, in each of which two semiconductor switches in the form of power transistors are disposed, for instance MOSFETs or also IGBT.
  • the transformer has a power unit with power transistors for the generation of a three-phase output alternating voltage, a capacitor battery as a buffer capacity and a triggering electronics for the power transistors.
  • a control unit is provided which has a computing unit with appendant software. Power transistors as well as control units are conveniently disposed on one circuit mounting plate. The power transistors generate considerable heat, which has to be discharged onto the surroundings with the aid of corresponding cooling attachments or the like.
  • a transformer has become known, in which all the power transistors are arranged on a first current bar as parallel connected semiconductor branches of the three-phase bridge, and the power transistors of the respective other half-branch of the bridge are disposed on a separate current bar per phase, on which the respective phase voltage is picked up.
  • the power transistors are in direct thermal contact with the current bars, which are part of a cooling attachment at the same time.
  • the cooling attachment is provided with three oblong portions disposed parallel in a distance, the transistors of each phase being attached alternately side by side in an insulated manner on one portion.
  • Mounting plate portions are disposed in the two compartments between the cooling attachment portions, with which the transistors and the capacitors of the capacitor battery are connected, the mounting plate portion disposed in the wider compartment having two rows of transistors.
  • an arrangement of three parallel current bars running in a distance is provided, respectively, of which a first current bar is provided for one phase, a second current bar for the minus potential and a third current bar for the plus potential.
  • the invention has as an objective to provide a driving system with converter control for three-phase motors, in which a high power density is obtained at relatively low manufacturing expenditure.
  • the power unit has a first printed circuit board which consists of a fairly heat-conductive material and which is disposed on the fairly heat-conductive bottom of the casing in a plane fitting arrangement.
  • the material of the first printed circuit board is electrically insulating in fact, but is of such a nature that a good heat conductivity exists.
  • the first printed circuit board may consist of an aluminium powder that is compounded with plastic material, whereby heat can be discharged in plane contact to the fairly heat-conductive bottom of the casing.
  • the interconnection traces in the first printed circuit board can be disposed such that they have plane contact to the bottom of the casing on their part. In this case, the casing bottom must not be electrically conductive.
  • the casing can be made from a fairly heat-conductive material, e.g. aluminium which is formed by the diecasting method.
  • the power transistors are disposed as well as a series of contact or connecting pins, which are soldered on the circuit board and which mechanically and electrically connect the first printed circuit board with the second printed circuit board, which is disposed parallel and in a distance above the first printed circuit board.
  • the so-called triggering unit for the power transistors as well as the required capacitor battery.
  • the second printed circuit board consists of a different base material, e.g. of glass fiber reinforced plastic material which is provided with copper linings or the like.
  • the contact pins extend through openings of the second printed circuit board and are preferably soldered in these openings, so that a solid mechanical joint is also established in this manner.
  • the arrangement of first printed circuit board and second printed circuit board is formed as a sandwich assembly, which can be attached to the bottom of the casing by screwing.
  • first printed circuit board On the first printed circuit board are also located the contact points for the alternating and direct current connections, with terminal pins being provided which are attached to these connections and which are lead through via openings in the second printed circuit board and the cover of the casing.
  • a transformer of the described type requires beyond that a so-called control unit, which is preferably also disposed within the casing, namely on the bottom side of the cover, the control unit being connected to the circuitry of the second printed circuit board via a cable, for instance a flat ribbon cable.
  • a control unit which is preferably also disposed within the casing, namely on the bottom side of the cover, the control unit being connected to the circuitry of the second printed circuit board via a cable, for instance a flat ribbon cable.
  • the first printed circuit board can be manufactured all automatically, especially by the so-called SMD (service mounted device) method.
  • the second printed circuit board can be assembled widely automatically also.
  • the inventive form of the driving system with a converter unit makes possible an excellent carrying off of the heat of the power transistors and through this a high power density, which leads to a corresponding saving of space and a compact construction.
  • the contact pins soldered on the first printed circuit board can be made of a springable yielding material and can have an outward bend or another design in the bottom region, such that the contact pins springably yield upon axial charge.
  • the contact pins may have an s-shape in the bottom region, for instance.
  • the contact pins are provided with an enlargement between the ends, on which a frame between first and second printed circuit board is supported, the pins extending in the upward direction through openings in the frame.
  • the frame has a stabilisation and alignment function, so that the upper ends of the contact pins are in the prescribed arrangement relatively accurate to size, when the second printed circuit board is placed upon. In this way it is possible to attach the second printed circuit board all automatically, the upper ends of the contact pins overhanging through the openings in the second printed circuit board and being soldered therein.
  • the contact points on the first printed circuit board are formed by sockets or pivots, which are soldered on the first printed circuit board in plane fitting, e.g. by the SMD-method.
  • the terminal pins are provided with a sleeve portion, which is pushable up to the socket. By the fact that the terminal pin is pushed up to the socket, the pin can yield in the rotational as well as in the axial direction, so that forces acting upon the terminal pin are not transferred to the first printed circuit board.
  • a portion of the cover to consist of plastic material, in the openings of which the upper ends oft the terminal pins are fixedly arranged.
  • this plastic material portion is cast into a recess or an indentation of the cover.
  • the terminal pins can be provided with a radial flange, which engages into a recess of the cover portion so that it is secured against rotation.
  • a ring nut can co-operate by an external thread with an internal thread of the recess, and thus tighten the flange against the bottom of the recess.
  • it can be provided with an outer toothing, preferably a saw-toothing, which co-operates with the wall of the recess in the cover portion in order to avoid any reverse rotation.
  • FIG. 1 shows a transformer unit according to the invention, broken-up and in perspective.
  • FIG. 2 shows the unit according to FIG. 1 in an extended representation, also in perspective.
  • FIG. 3 shows the sandwich assembly of first and second printed circuit board of the transformer unit according to FIGS. 1 and 2 .
  • FIG. 4 shows the bottom side of the cover of the unit according to FIG. 1 or 2 in perspective.
  • FIG. 5 shows the top view of the first printed circuit board of the sandwich assembly according to FIG. 3 .
  • FIG. 6 shows the first printed circuit board according to FIG. 5 in perspective.
  • FIG. 7 shows a section through the printed circuit board along the line 7 — 7 .
  • FIG. 8 shows a partial section through the first and second printed circuit board according to FIG. 3
  • FIG. 9 shows the top view of a portion of the cover of the transformer unit along the line 10 — 10 .
  • FIG. 10 shows a section through the delineation according to FIG. 9 along the line 10 — 10 .
  • a driving system with a transformer is generally denomitated with 10 . It is provided with a casing with a casing bottom portion 12 and a cover 14 .
  • the cover co-operates in a sealing manner with the casing bottom portion, the cover 14 being screwed together with the casing bottom portion 12 , to which is not incurred in detail, however.
  • Casing bottom portion 12 and cover 14 are formed by aluminium die casting, for instance, but in particular by a fairly heat conductive material.
  • a portion 16 of plastic material is injected in an upper recess or indentation of the cover 14 .
  • the portion 16 is provided with five recesses or indentations, one of which can be particularly well recognised at 18 .
  • the bottom of the recess 18 is provided with an opening, which corresponds to an opening in a depression 20 of the cover 14 . Through these openings, a terminal pin 22 extends in the upward direction.
  • a total of five terminal pins 22 are provided.
  • the two terminal pins disposed on the left border of the cover 14 in FIG. 1 form the connection for direct current which is delivered from a battery (not shown).
  • the three terminal pins 22 arranged in series parallel to the latter form the three-phase current outputs, which are connected to a not shown three-phase ac motor of a floor conveyor.
  • the fixation of the terminal pins 22 will still be described below.
  • the terminal pin tagged with the index 22 and its fixation, respectively, is represented in an assembly phase, i.e. the parts used for them are not yet on their definite place, as is shown with respect to the other contact pins.
  • a first printed circuit board 24 can be easily recognised and a second printed circuit board 26 , which is arranged parallel and in a distance above the first printed circuit board 24 .
  • the printed circuit boards 24 , 26 form a sandwich assembly.
  • the substrate material of the printed circuit board 24 consists of e.g. aluminium which is compounded with plastic material, whereas that for the printed circuit board 26 consists of glass fiber reinforced plastic material.
  • the printed circuit board 24 is fairly heat-conductive. It is applied in a plane manner to the bottom of the casing portion 12 , as can be recognised from FIG. 1 , so that a good carrying off of heat can be achieved, because the first printed circuit board 24 contains the power unit of the transformer, particularly the power transistors, which are soldered on the printed circuit board 24 , as is shown at 28 in the form of little boxes, for instance.
  • Contact pins are also soldered on the first printed circuit board 24 , namely group-wise or separately, as can be recognised at 30 .
  • the attachment of the contact pins and their forms emerges in more detail from FIG. 8 .
  • the flat contact pins 30 formed from sheet metal are bent in an s-shape on the bottom end, the bottom branch of the s being soldered on the printed circuit board 24 in a plane across a larger range. Upside the s-form the contact pins 30 are provided with an enlargement 34 , on which a frame 36 is seated, through the holes of which the contact pins 30 extend in the upward direction.
  • Such frames can be recognised in the FIGS. 1 , 5 and 6 , for instance.
  • These frames have the objective to maintain the numerous contact pins of a contact pin arrangement in a determined alignment, because the upper printed circuit board 26 is disposed such that the upper ends of the contact pins 30 extend through corresponding holes of the printed circuit board 26 , as can be clearly recognised in FIG. 8 but also in FIG. 1 .
  • the contact pins 30 are soldered with the upper printed circuit board 26 in the known manner, by which corresponding connections with the interconnection traces of the second printed circuit board 26 are produced.
  • the contact pins 30 are connected with interconnection traces of the first printed circuit board 24 , which on their part are lead to the transistors. In this way the second printed circuit board 26 is not only electrically but also mechanically connected to the first printed circuit board 24 for the formation of the sandwich assembly according to FIGS. 2 and 3 .
  • the particular form of the contact pins 30 makes a vibration-reduced support of the second printed circuit board 26 possible, so that vibrations do not directly act upon the soldering points.
  • the sockets 38 are disposed on the first printed circuit board 24 . They are provided with a flange 40 , which is soldered to the first printed circuit board 24 in a plane. A pivot 42 extends from the flange 40 in the upward direction.
  • the sockets 38 form the connections for the terminal pins 22 for direct and alternating current.
  • the transistors as well as the sockets 38 can be attached to the first printed circuit board 24 by a so-called SMD (Service Mounted Device) method, which can take place all automatically.
  • the second printed circuit board 26 comprises the so-called triggering unit for the power semiconductors, the second printed circuit board being also producible almost all automatically by the SMD-Method. It is not incurred to further to the assembly of the second printed circuit board.
  • the capacitors 27 should be mentioned, however. The bottom ones are fixed on the second printed circuit board and the upper ones on two extra mounting plates, which are connected by a screw joint to the second printed circuit board.
  • the terminal pin 22 has a sleeve portion 44 on the bottom end, which is formed such that it can be pushed up on the pivot 42 in order to establish an electrical connection.
  • the sleeve portion 44 may be formed in a corresponding manner, which shall not be described in detail, however.
  • the flange 46 is situated upside of an opening in the recess 18 of the cover portion 16 or an opening in the cover 14 , respectively.
  • the recess 18 which is approximately circular and is provided with five radially projecting parts 48 disposed in equal perimeter spacing on its bottom part, which co-operate with correspondingly formed recesses 50 of the flange 46 in order to secure the latter against rotation (see especially FIG. 9 ).
  • the fixation of the terminal pin 22 in the cover portion 16 takes place with the aid of a straining ring nut 52 , which is provided with an external thread 54 , which co-operates with an internal thread 56 in the recess 18 .
  • the flange 46 can be strained against the bottom of the recess and also be fixed in its angular position.
  • the straining ring 52 is provided on its upper end with a radial flange 58 pointing in the outward direction which is provided with a saw-toothing 60 , as can be recognised in FIG. 9 .
  • the saw toothing co-operates with the opposing wall of the recess 18 , whereby the straining ring 52 is secured against rotation and can not self-acting unscrew itself.
  • a third printed circuit board 64 is attached to the bottom side of the cover 14 by screwing.
  • This third printed circuit board 64 contains the control unit for the triggering unit, which is located on the second printed circuit board 26 .
  • 66 serves to the discharge of heat of a circuitry component of the circuit mounting plate 26 situated thereunder as a kind of cooling unit.
  • the attachment of the cover 14 on the casing portion 12 takes place by a screwing, as already described.
  • the sandwich assembly of first and second printed circuit board according to FIG. 3 is also fixed on the bottom of the casing porting 12 with the aid of screws.
  • the power module which is built on an IMS (Intelligent Manufacturing System) base, can be assembled all automatic with the aid of SMD technology.
  • the second printed circuit board 26 can also be assembled for the most part via SMD.
  • the sandwich assembly made from the first and the second printed circuit board allows for an optimal economy of space.
  • the delineated association of the power connections is thermally optimal.
  • a mechanical uncoupling and adaptation of the sandwich assembly is obtained by means of the outlined plug-in system, whereby a compensation of all the vertical and horizontal tolerances is also achieved. Torques which occur on the terminal pins are absorbed by the cover and do not reach the sandwich assembly.
  • a vibration-reducing and a thermal uncoupling takes place between the printed circuit board and the triggering printed circuit board.
  • the electromagnetic noise transmission concerning the so-called electromagnetic compatibility is reduced and the electromagnetic irradiation resistance is optimised.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)
  • Casings For Electric Apparatus (AREA)
  • Mounting Of Printed Circuit Boards And The Like (AREA)
US10/429,287 2002-05-04 2003-05-02 Driving system with converter control for low-voltage three-phase motors Expired - Lifetime US7006356B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10220047A DE10220047A1 (de) 2002-05-04 2002-05-04 Antriebssystem mit Umrichtersteuerung für Niederspannungs-Drehstrommotoren
DE10220047.5 2002-05-04

Publications (2)

Publication Number Publication Date
US20040022041A1 US20040022041A1 (en) 2004-02-05
US7006356B2 true US7006356B2 (en) 2006-02-28

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US10/429,287 Expired - Lifetime US7006356B2 (en) 2002-05-04 2003-05-02 Driving system with converter control for low-voltage three-phase motors

Country Status (4)

Country Link
US (1) US7006356B2 (de)
EP (1) EP1359662B1 (de)
CN (1) CN1285165C (de)
DE (2) DE10220047A1 (de)

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DE102015209279A1 (de) * 2015-05-21 2016-11-24 Robert Bosch Gmbh Elektrische Kontaktanordnung
DE102015224073A1 (de) * 2015-12-02 2017-06-08 Zf Friedrichshafen Ag Mehrfunktionale Hochstromleiterplatte
EP3206468B1 (de) * 2016-02-15 2018-12-26 Siemens Aktiengesellschaft Umrichter mit gleichspannungszwischenkreis
DE102016110052B4 (de) * 2016-05-31 2018-10-04 Endress+Hauser SE+Co. KG Feldgerät mit einer gekapselten Leiterplatte sowie Verfahren zur Kapselung einer Leiterplatte eines solchen Feldgerätes
US11458856B2 (en) * 2019-03-08 2022-10-04 Auto Motive Power, Inc. Combined BMS, charger, and DC-DC in electric vehicles
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JP6884241B1 (ja) * 2020-01-29 2021-06-09 三菱電機株式会社 半導体装置
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CN1285165C (zh) 2006-11-15
EP1359662B1 (de) 2006-06-21
DE50303901D1 (de) 2006-08-03
DE10220047A1 (de) 2003-11-20
CN1455506A (zh) 2003-11-12
EP1359662A1 (de) 2003-11-05
US20040022041A1 (en) 2004-02-05

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